TW201632355A - Flame retardant planar element and floor covering hardly generating hazardous gas using the flame retardant planar element, and production method of the floor covering hardly generating hazardous gas - Google Patents

Abstract

The present invention provides an entirely novel flame retardant planar element which offers optimum cushioning properties, flexibility and elasticity, while improving the function of hardly generating hazardous gas by providing additional flame resistance beyond the original flame retardancy and fire resistance. Also provided are a floor covering hardly generating hazardous gas which uses the flame retardant planar element, and a method of manufacturing the floor covering hardly generating hazardous gas. The flame retardant planar element of the invention has a flexible planar main body that can be used in floor coverings hardly generating hazardous gas or the like, and on at least one surface or another surface of this flexible planar main body is provided a thermoplastic resin layer which contains at least an inorganic substance such as sodium polyborate and comprises one or other of an acetyl group or low-temperature characteristics, and/or the flexible planar main body itself contains at least an inorganic substance such as sodium polyborate and has kneaded therein a thermoplastic resin comprising one or other of an acetyl group or low-temperature characteristics.

Description

Flame-retardant planar body, mat for using the flame-retardant planar body which is less likely to generate harmful gas, and method for manufacturing the mat which is less likely to generate harmful gas

The present invention relates to a flame-retardant planar body, a mat for using the flame-retardant planar body which is less likely to generate a harmful gas, and a method for manufacturing the mat which is less likely to generate a harmful gas, and the flame-retardant planar body is not limited to a train, Interior materials such as automobiles, wall materials or ceiling materials for furniture or buildings, when used for mats, are not only suitable for floors of ships, airplanes, etc., but also for floors of various buildings, with flameproof It is flame retardant and does not easily generate harmful gases even when heated. In addition, in the present invention, a mat which is less likely to generate a harmful gas using a flame-retardant planar body refers to a mat which is confirmed by a test method of a smoke generation and a combustion toxicity test.

In recent years, in order to minimize the damage caused by fire, materials such as fire-resistant and fire-resistant materials are often used for houses, furniture, mats, and the like, and it is particularly desirable to use a material that is resistant to flame retardant fire resistance caused by harmful gases. In addition, when a fire occurs in a place where there is no place to escape, such as a ship, it will develop into a serious disaster with a large number of casualties, and it will be in a serious state of affairs, so it is not only for flame retardancy and fire resistance but also for flame resistance and harmful gases. Since the inventors have developed a strict standard, the inventors of the present invention developed Japanese Patent No. 4,351,220, and developed a mat which is excellent not only in flame retardancy but also in fire resistance and in flame resistance, and which makes it difficult for harmful gases to occur.

That is, the invention is a mat which is less prone to generate harmful gases, and the substrate material layer and the skin material layer are bonded by a layer of a bonding material, and the substrate material layer is composed of oxidized acrylic fibers and polyester fibers. The non-woven fiber aggregate of the mixed cotton is formed, and the blending ratio is 30 to 80% by weight of the oxidized acrylic fiber and 20 to 70% of the polyester fiber. The adhesive material layer is composed of a flat woven mesh bottom amorphous olefin polymer composition composed of a multifilament yarn containing polyester fibers, and the skin material layer is a primary base composed of a polyester fiber nonwoven fabric. The surface of the cloth is formed into a pile by a pile yarn of 100% wool, and the back surface is coated with an adhesive composed of an amorphous olefin polymer composition for preventing the off-line, and the liquid incombustible material is attached. On the surface of the layer of skin material.

According to the mat which is less likely to generate a harmful gas, the raw material as a whole is a material which is less likely to generate a harmful gas, and exhibits the effect of providing the market with a mat which is not only flame-retardant but also flame-resistant and flame-resistant, thereby making it difficult to generate harmful gas.

Further, as a technique for imparting flame retardancy to the above mat, there is a technique in which a flame retardant such as an organic phosphorus compound is applied to a resin or sodium polyborate is kneaded to a resin material. [Patent Document] Japanese Patent Publication No. 4,351, 092

[The problem that the invention wants to solve]

However, the mat which is less likely to generate a harmful gas as disclosed in the above-mentioned Japanese Patent No. 4,351,220 can exert the following special effects: not only flame retardancy but also fire resistance and flame resistance so that harmful gases are not easily generated; As a mat, it is better to have better cushioning when walking. Further, the cushioning property of the mat is borne by the nonwoven fabric aggregate of the skin material layer and the backing material layer, in the skin material layer, although by the surface of the primary base fabric composed of the polyester fiber nonwoven fabric The pile yarn of 100% wool forms a pile fabric with a certain degree of cushioning property, but it is particularly desirable to develop a substrate material layer which has not only flame retardancy but also fire resistance and flame resistance so that harmful gases are not easy The resulting function, and also has the best cushioning.

Further, according to the above-mentioned mat which is less likely to generate a harmful gas, it is of course necessary to cut a long rug which is a predetermined width and a predetermined length when used, whether by using a cutting process as a tile carpet. When it is used, it is not only transported from a manufacturing plant or the like to a construction site, but also moved to an actual construction site during moving to the actual construction site, etc., and can be bent or softened, so that workability is good.

Furthermore, during construction, the following problems occur: if there is no degree of flexibility and stretchability, it is easy to peel off. In any case, it is desired to develop a mat having a brand-new substrate material layer which is less prone to generate harmful gases, and in the substrate material layer, it has not only sufficient flame retardancy but also fire resistance and flame resistance so that harmful gases are hard to be produced. Functional and with some degree of softness or flexibility.

Further, in the mat which is less likely to generate a harmful gas, when a flame retardant such as an organic phosphorus compound is applied to the resin, not only the adhesion of the phosphorus compound to the resin is insufficient, but also when the sodium polyborate is kneaded to the resin material, When the polyborate is kneaded to a vinyl chloride resin or an olefin resin at a kneading temperature (150 ° C or higher), a part of the sodium polyborate is foamed, and the problem is not only the case, but also a hydroxyl group in the structure depending on the resin material. When the amount is small, the affinity with sodium polyborate is weak, the amount of adhesion in coating or coating is reduced, and the flame retarding effect is insufficient. [How to solve the problem]

In order to solve the above-mentioned problems, the present invention has developed a flame-retardant planar body having a sufficient flame-retardant effect, and a new flame retardant having cushioning properties and flexibility and stretchability while using the flame-retardant planar body. The following methods are used for the method of producing a surface-faced body and a mat which is less likely to generate a harmful gas using the flame-retardant planar body and the mat which is less likely to generate harmful gas.

The flame-retardant planar body according to the first aspect of the present invention is characterized in that it is applicable to at least one of one side or the other surface of a flexible planar body such as a mat (A) which is less likely to generate a harmful gas. The thermoplastic resin layer is provided with at least one of an ethylene group or a low temperature specificity, and at least one of an ethylenic group or a low temperature specificity; and/or a thermoplastic resin is mixed in the flexible planar body itself. Further, the thermoplastic resin has at least one of an ethylene group and an inorganic substance such as sodium polyborate, and has at least one of an ethylene group and a low temperature specificity.

Further, the flame-retardant planar body according to the second aspect is characterized in that the thermoplastic resin is formed of a coating layer or an EVA-based resin layer. The coating layer is an EVA emulsion containing at least sodium polyborate in the ethylene-vinyl acetate copolymer and dried. The EVA-based resin layer contains at least sodium polyborate in the ethylene-vinyl acetate copolymer.

Further, in the flame-retardant planar body according to the third aspect, when the EVA-based emulsion coating layer is provided on at least one of one surface and the other surface of the flexible planar body, the EVA-based resin laminated layer is The EVA emulsion is coated on the layer.

Further, the flame-retardant planar body according to the fourth aspect is characterized in that, when a thermoplastic resin layer is provided on one surface or the other surface of the flexible planar body, the flexible planar body opposite to the thermoplastic resin layer A pile fabric is formed on one or the other side.

Further, the flame-retardant planar body according to the fifth aspect is characterized in that another flexible planar body is laminated on one surface or the other surface of the flexible planar body opposite to the surface on which the pile fabric is formed. Further, at least one of the EVA-based emulsion coating layer or the EVA-based resin layer is provided on at least one of the one surface or the other surface of the other flexible planar body.

Further, the flame-retardant planar body according to the sixth aspect is characterized in that the substrate material is laminated on the thermoplastic resin layer.

Further, the flame-retardant planar body according to the seventh aspect is characterized in that the thermoplastic resin layer or the substrate material layer is provided with a suppressing mechanism for suppressing shrinkage or bending of the flame-retardant planar body. At least either side.

Further, the flame-retardant planar body according to the eighth aspect is characterized in that at least one of the vibration-proof device or the sound absorbing device is provided in any one of the flexible planar body, the thermoplastic resin layer or the substrate material layer. One party.

Further, the flame-retardant planar body according to the ninth aspect is characterized in that the flame-retardant planar body contains a radiation shielding substance.

Further, the flame-retardant planar body according to the tenth aspect, wherein the substrate material layer is a nonwoven fabric in which at least one of pitch-based carbon fibers or PAN-based carbon fibers and polyester-based fibers are blended. The volume ratio of the pitch-based carbon fiber or the PAN-based carbon fiber is 30 to 80% by weight, the polyester fiber is 20 to 70% by weight, and the width of each fiber is 2.0 to 16.0. Dtex, the cutting length is formed in the range of 20~160mm.

Further, the flame-retardant planar body according to the eleventh aspect is characterized in that the weight of the substrate material layer (10) is 0.01 to 1.5 kg/m ² .

Further, the flame-retardant planar body according to the twelfth aspect is characterized in that the substrate material layer (10) is suppressed in a range of 3.0 to 15.0 mm by a needle rolling method or the like.

Further, according to the thirteenth aspect, the mat (A) which is less prone to generate harmful gas using the flame-retardant planar body is characterized in that the skin material layer (20) is defined so as to form the pile fabric (22). The flame-retardant planar body is used as a primary base fabric (21), and the skin material layer (20) and the substrate material layer (10) are sandwiched between the thermoplastic resin layer and/or other bonding. The material layer (30) is laminated. Further, the thermoplastic resin layer and/or the other adhesive material layer (30) may be made to have flame retardancy to form the skin material layer (20) by containing or not including a plain weave mesh bottom. The planar body and the substrate material layer (10) are integrated.

Further, a method for producing a mat which is less likely to generate a harmful gas according to the fourteenth aspect is characterized in that it is cut into a predetermined size by any of the following steps to produce a mat which is less likely to generate a harmful gas: Forming a substrate material layer (10) The substrate material layer (10) is a pitch-based carbon fiber formed by a fiber having a thickness of 2.0 to 16.0 dtex and a cutting length of 20 to 160 mm or a fiber thickness of 2.0 to 16.0 dtex. At least one of PAN-based carbon fibers formed in a range of 20 to 160 mm in cutting length, and a polyester-based fiber formed in a range of 2.0 to 16.0 dtex and a cutting length of 20 to 160 mm in the thickness of the fiber, and the asphalt The blending ratio of at least one of the carbon fibers and the PAN-based carbon fibers is 30 to 80% by weight, and the polyester fibers are 20 to 70% by weight, and the mixture is composed of a nonwoven fabric aggregate. a step of forming a flame-retardant planar body having an EVA-based emulsion coating layer or at least one of one surface or the other surface of a flexible planar body formed of a polyester fiber or the like At least one of the EVA-based resin layers. The EVA emulsion coating layer is an EVA emulsion containing at least sodium polyborate in an ethylene-vinyl acetate copolymer and dried. The EVA-based resin layer contains at least sodium polyborate in the ethylene-vinyl acetate copolymer. Forming a skin material layer (20), forming a pile fabric (22) on the surface of one side of the flame-retardant surface by a pile yarn, so that the flame-retardant surface is regarded as a primary cloth (21) The skin material layer (20) is formed to be used. And a step of laminating and superimposing and superimposing and bonding, the EVA-based resin layer provided on the back surface of the flame-retardant planar body formed as the skin material layer (20), and the lining Between the bottom material layers (10), a plain weave mesh bottom is inserted or not inserted, so that the EVA-based resin layer is used as a bonding material layer, and the substrate material layer (10) and the skin material layer are formed. (20) a flame-retardant planar laminate combined with pressure heating for lamination bonding, or a benzene for preventing off-line coating on the back surface of the flame-retardant surface forming the pile fabric (22) An adhesive of at least one of the ethylene-butadiene-styrene block copolymer composition or the amorphous olefin polymer composition, and after forming the skin material layer (20), the substrate material layer ( 10) After coating (adhesive material layer 30) with a paste using either a styrene-butadiene-styrene block copolymer composition or an amorphous olefin polymer composition, the stack Closing the bottom of the mesh, then heating it, and then forming a barrier to the skin material layer (20) thereon The combined stack of the planar body is pressurized and heated, laminated bonding.

Further, the thermoplastic resin layer which can be used in the flame-retardant planar body according to the fifteenth aspect is characterized in that the thermoplastic resin layer and/or the emulsion is an ethylene-vinyl acetate copolymer or the like having an ethylene group or a low temperature. At least one of the specificities includes at least an inorganic substance such as sodium polyborate and a sheet or liquid having a predetermined thickness.

Further, the thermoplastic resin according to the sixteenth aspect, further comprising: a reinforcing mechanism for preventing cracking of the thermoplastic resin layer or the like when the thermoplastic resin layer formed in a sheet shape or a mat shape is bent or pushed or pulled Damage such as cutting. [Effects of the Invention]

In the flame-retardant planar body of the present invention, at least one of one surface or the other surface of the flexible planar body which can be used in a mat (A) or the like which is less likely to generate a harmful gas is provided with a thermoplastic resin layer. At least one of an acetyl group or a low temperature specificity is contained in an inorganic substance such as sodium polyborate; and/or a thermoplastic resin is mixed in the flexible planar body itself, wherein the thermoplastic resin has at least sodium polyborate It is an inorganic substance, and has at least one of an ethylene group or a low temperature specificity. Therefore, when an ethylene group is present in the thermoplastic resin, the hydrogen bond strongly acts on both the sodium polyborate and the flexible planar body, and a flame-retardant planar body excellent in flame retardancy can be formed. In addition, when it has a low temperature specificity, it has the following effects: it can effectively knead the thermoplastic resin without foaming the sodium polyborate; wherein the low temperature specificity is that the melting point of the thermoplastic resin is lower than that of the normally harmful gas. A substrate material used in a mat or the like, such as vinyl chloride or the like. Further, by using an inorganic substance such as sodium polyborate, there is an effect that not only does the load on the environment occur, but also harmful chemicals such as a sick house are not generated.

Further, the thermoplastic resin layer contains at least an EVA-based emulsion coating layer in which an EVA-based emulsion containing at least sodium polyborate is coated with an ethylene-vinyl acetate copolymer, or an ethylene-vinyl acetate copolymer contains at least a poly When at least one of the EVA-based resin layers of sodium borate is formed, the ethylene-vinyl acetate copolymer (EVA) is excellent in low-temperature specificity, low in specific gravity, high in impact strength, and soft and non-toxic. Further, it has an effect of lowering the low temperature specificity such as vinyl chloride or the like which is generally used for a substrate material or the like, and it is possible to efficiently knead the sodium polyborate without foaming it. Further, since the ethylene-vinyl acetate copolymer resin has an ethylene group, the hydrogen bond strongly acts on both the sodium polyborate and the flexible planar body (for example, when formed by a polyester fiber nonwoven fabric or the like) and can form a resistance. The flame-retardant planar body having excellent flammability not only has the above advantages, but also an inorganic substance such as sodium polyborate can be used, and it is possible to prevent the generation of harmful chemicals such as a diseased house.

In the case where the flame-retardant planar body is provided with an EVA-based emulsion coating layer on at least one of the one surface and the other surface of the flexible planar body, the EVA-based resin laminated layer is applied to the EVA-based emulsion coating layer. The effect of further improving the flame retardancy of the flame-retardant planar body can be achieved.

When a thermoplastic resin layer is provided on one surface or the other surface of the flexible planar body of the flame-retardant planar body, a pile fabric is formed on one surface or the other surface of the flexible planar body opposite to the thermoplastic resin layer, and has the following effects. A flame-retardant planar body excellent in flame retardancy can be used as a primary base fabric such as a mat which is less likely to generate a harmful gas.

Further, in the flame-retardant planar body, another flexible planar body is laminated on one side or the other side of the flexible planar body facing the pile fabric, and the other flexible planar body is When at least one of the EVA-based emulsion coating layer or the EVA-based resin layer is provided in at least one of the one surface and the other surface, the following effects are exerted: not only the tensile strength of the flame-retardant planar body but also the tensile strength of the flame-retardant planar body can be further improved. The cutting dimensional stability at the time of cutting into a predetermined size is improved, and the flame retardancy is further improved.

In addition, when the base material layer is laminated on the thermoplastic resin layer of the flame-retardant planar body, the thermoplastic resin layer (EVA-based emulsion coating layer or EVA-based resin layer) functions to promote flame retardancy. The action and the bonding action can provide a flame-retardant planar body having a substrate material layer which is not easily deviated.

In addition, when one of the flexible planar body, the thermoplastic resin layer, or the substrate material layer of the flame-retardant planar body is provided, at least one of the suppression mechanism for suppressing shrinkage or bending of the flame-retardant planar body is provided. It has the effect that the flame-retardant planar body cut into a predetermined size can be arranged in a gapless manner in all places such as a wall, a ceiling, and a floor by an adhesive or the like.

In addition, when at least one of the vibration-proof device or the sound absorbing device is provided in any one of the flexible planar body, the thermoplastic resin layer, or the substrate material of the flame-retardant planar body, the following effects are obtained: vibration or desire to mute Each of the places may be provided with a flame-retardant surface by an adhesive or the like.

In addition, the flame-retardant planar body may contain a radiation shielding material. For example, the EVA resin is excellent in miscibility with a radiation shielding material such as tungsten or lead. Therefore, if the radiation shielding substance is contained in the EVA-based resin layer, It exhibits the effect that a flame-retardant planar body having added value in addition to flame retardancy can be obtained, and the added value is radiation shielding property.

In addition, the substrate material layer provided in the flame-retardant planar body is composed of at least one of pitch-based carbon fibers or PAN-based carbon fibers and a nonwoven fabric aggregate such as polyester-based fibers, and the blending ratio is as follows: At least one of the pitch-based carbon fiber or the PAN-based carbon fiber is 30 to 80% by weight, the polyester fiber is 20 to 70% by weight, and the width of each fiber is 2.0 to 16.0 dtex and the cutting length is 20 to 160 mm. Since it is formed in the range, it has the following effects: not only flame retardancy and fire resistance, but also flame resistance, so that it has a function of making harmful gases difficult to generate, and also has optimum cushioning properties.

Further, when the weight of the substrate material (10) provided in the flame-retardant planar body is 0.01 to 1.5 kg/m ² , the following effects can be obtained: the substrate material (10) itself can be made to have both flexibility and Scalability.

Further, the substrate material layer (10) provided on the flame-retardant planar body is suppressed to a thickness of 3.0 to 15.0 mm by a needle rolling method or the like, thereby exerting the following effect: the substrate material can be made The layer itself is both flexible and stretchable.

Further, according to the mat (A) which uses a flame-retardant planar body which is less likely to generate a harmful gas, the skin material layer (20) is formed to have a pile fabric (22) (for example, a nonwoven fabric made of polyester fiber). The flame-retardant planar body of the pile yarn of 100% wool formed on the surface of the base fabric is used as the primary base fabric (21), and the skin material layer (20) and the substrate material layer (10) are used. The laminate is formed by laminating the thermoplastic resin layer and/or other bonding material layers (30). Further, the thermoplastic resin layer and/or other bonding material layer (30) (for example, using at least one of a styrene-butadiene-styrene block copolymer composition or an amorphous olefin polymer composition) The formed substance or the like) is formed so as to form a flame-retardant surface of the skin material layer (20) with or without a plain weave mesh bottom (for example, a material formed of a multifilament yarn of polyester fiber). The body is integrated with the substrate material (10).

Therefore, according to the mat (A) which is less likely to generate a harmful gas, the heat setting property can be remarkably improved without lowering the flame resistance, and the high heat resistance such as a heat-resistant temperature of 150 to 200 ° C can be obtained, thereby providing high flame retardancy. It is flame-proof, so even if it is directly exposed to the flame, it will not generate harmful gas, and it can be extinguished in an instant and will not burn. In addition, the mat (A) which is less prone to generate harmful gases does not burn by itself. Therefore, even if the ignition of the substrate material itself is caused by, for example, a damage caused by melting, the damage is slight, and the special effect of providing optimum cushioning property, flexibility, or stretchability can be achieved. The optimum cushioning property is a mat (A) which is resistant to water and has good adhesion and has excellent durability in tensile strength and cutting dimensional stability. The flexibility or stretchability is, for example, in the case of use, when it is used as a carpet tile by cutting, or when it is cut into a long carpet having a predetermined width and a predetermined length, in any of the above cases, When it is transported to a construction site or the like from a manufacturing plant or the like, it can be bent or wound softly when it is moved to the actual construction site at the construction site, etc. The softness or stretchability of peeling.

Further, the thermoplastic resin layer and/or the emulsion contains at least one of an ethylene group such as an ethylene-vinyl acetate copolymer or a low-temperature specificity, and at least contains an inorganic substance such as sodium polyborate, and at the same time, if it has a fixed When the thickness is in the form of a sheet or a liquid, it has the following effects: it is not necessary to use a flexible planar body, and it can be used in various places such as flooring, automobiles, trains, airplanes, and the like, such as floor mats and/or interior materials. The sheet-shaped thermoplastic resin is used as a flame-retardant member which does not cause a load on the environment and can prevent the generation of harmful chemicals such as a diseased house, or as a flame-retardant spray or a flame-retardant adhesive. In multiple areas.

Further, in the thermoplastic resin layer, when the sheet-shaped thermoplastic resin layer is bent or pushed, the reinforcing resin is provided to prevent breakage of the thermoplastic resin layer, such as cracking or cutting, and the like. Provided as a thermoplastic resin, it is possible to increase the strength of the thermoplastic resin layer itself which is insufficient in strength especially for tensile strength, and to produce a defective product, not only in the production of various types of places, but also in the production.

Hereinafter, an embodiment of a flame-retardant planar body of the present invention, a mat which is less likely to generate a harmful gas using the flame-retardant planar body, and a method for producing the mat which is less likely to generate harmful gas will be described with reference to the accompanying drawings. In the present invention, the coating-dried layer of an emulsion containing at least sodium polyborate in the vinyl acetate copolymer is expressed as an EVA-based emulsion coating layer, or the vinyl acetate copolymer contains at least sodium polyborate. The resin is expressed as an EVA-based resin layer.

In the method of manufacturing the mat A which is less likely to generate a harmful gas, the flame-retardant planar body which can be used as the primary base fabric 21 of the mat A which is less likely to generate a harmful gas will be described. The flame-retardant planar body is not particularly limited in material. For example, at least one of one surface or the other surface of the flexible planar body formed of the polyester-based nonwoven fabric is provided with a thermoplastic resin layer. The thermoplastic resin layer contains at least one of an acetyl group or a low temperature specificity, and contains at least an inorganic substance such as sodium polyborate. Therefore, although the type of the thermoplastic resin or the like is not particularly limited, when the ethylene group is present in the thermoplastic resin, the hydrogen bond is strongly applied to both the sodium polyborate and the flexible planar body to form excellent flame retardancy. Flame retardant surface. Further, when it has a low temperature specificity, it has an advantage that it can be efficiently kneaded with a thermoplastic resin without foaming sodium polyborate. The low-temperature specificity thermoplastic resin has a lower melting point than a substrate material which is generally used for a mat or the like which does not easily generate a harmful gas, such as vinyl chloride.

More specifically, when the thermoplastic resin is formed of at least one of an EVA-based emulsion coating layer or an EVA-based resin layer, the ethylene-vinyl acetate copolymer resin (EVA) is excellent not only in low temperature specificity but also low in specificity. Specific gravity and high impact strength, and soft, non-toxic. Further, it has an effect of lowering the low temperature specificity such as vinyl chloride or the like which is generally used for a substrate material or the like, and it is possible to efficiently knead the sodium polyborate without foaming it. The EVA emulsion coating layer is an EVA emulsion containing at least sodium polyborate in a vinyl acetate copolymer and dried. The EVA-based resin layer contains at least sodium polyborate in the vinyl acetate copolymer. Further, since the vinyl acetate copolymer resin has an ethylene group, the hydrogen bond strongly acts on both the sodium polyborate and the flexible planar body (for example, formed by a polyester fiber nonwoven fabric or the like), and can form a resistance. The flame-retardant planar body having excellent flammability not only has the above-described advantages, but also uses an inorganic substance such as sodium polyborate to prevent the occurrence of a load on the environment and prevent the occurrence of harmful chemical substances such as a diseased house.

In addition, when the EVA-based emulsion coating layer is provided on at least one of the one surface or the other surface of the flexible planar body, the flame-retardant planar body is applied to the EVA-based emulsion coating layer. The following advantages: The degree of flame retardancy of the flame-retardant planar body can be further improved.

Further, when a thermoplastic resin is provided on one surface or the other surface of the flexible planar body of the flame-retardant planar body, a pile fabric is formed on one surface or the other surface of the flexible planar body opposite to the thermoplastic resin layer. There is an advantage that a flame-retardant planar body excellent in flame retardancy can be used as a primary base fabric such as a mat which is less likely to generate a harmful gas.

Further, on one side or the other side of the flexible planar body opposite to the surface on which the pile fabric is formed, another flexible planar body is laminated on the flame-retardant planar body, and the other flexible planar body When at least one of the EVA-based emulsion coating layer or the EVA-based resin layer is provided in at least one of the one surface and the other surface, the flame-resistant planar body is used as a mat which is less likely to generate harmful gas. When the primary base fabric is used, the tensile strength of the flame-retardant planar body can be further improved, and the dimensional stability of the cut size when cut into a predetermined size can be improved, and the flame retardancy can be further improved.

In addition, when a base material layer is laminated on the thermoplastic resin layer of the flame-retardant planar body, the thermoplastic resin layer (EVA emulsion coating layer or EVA resin layer) functions to promote flame retardancy. As well as the bonding effect, it is also possible to obtain a flame-retardant planar body having a substrate material layer which is not easily deviated.

In addition, when any one of the flexible planar body, the thermoplastic resin, or the base material layer of the flame-retardant planar body has a suppressing mechanism for suppressing at least one of shrinkage or bending of the flame-retardant planar body, The advantages are as follows: the flame-retardant planar body cut to a predetermined size can be arranged in a gapless manner in all places such as walls, ceilings, and floors by an adhesive or the like. Here, the shrinkage or bending of the flame-retardant planar body means that the adhesive applied to the floor is absorbed by the main material of the flame-retardant planar body. Therefore, for example, a resin sheet such as polyethylene may be attached to prevent, for example, the adhesive from being absorbed by the substrate material layer, and it is not necessary to limit the specific mechanism for suppressing the shrinkage or bending of the specific flame-retardant planar body. Material, composition, etc.

Further, any one of the flexible planar body, the thermoplastic resin layer or the substrate material layer of the flame-retardant planar body may be provided with at least one of an anti-vibration device or a sound absorbing device. For example, when the content of vinyl acetate is increased in the EVA resin layer, the elasticity and flexibility are improved, and the vibration damping property and the sound absorbing property can be improved. Although there is no particular limitation on the specific vibration isolating device or the suction device, when at least one of them is provided, there is an advantage that a flame-retardant planar body can be attached by an adhesive or the like in an individual place where vibration or static stability is desired.

Further, the flame-retardant planar body may contain a radiation shielding substance, and for example, the mixing property of the EVA resin with a radiation shielding substance such as tungsten or lead is good. Therefore, when the radiation shielding material is contained in the EVA-based resin layer, it is advantageous in that a flame-retardant planar body having added value in addition to flame retardancy can be obtained, and the added value is radiation shielding property.

In addition, the thermoplastic resin layer and/or the emulsion is at least one of an ethylene group and a low temperature specificity such as an ethylene-vinyl acetate copolymer, and at least contains an inorganic substance such as sodium polyborate and a sheet having a predetermined thickness. In the case of liquid, it has the advantage that it is not necessary to use a flexible planar body, and the above-mentioned thermoplastic resin formed in a sheet shape can be used for various floor mats of walls, floors, automobiles, trains, airplanes, and the like. In all places, such as the interior materials, the market is expanded as a flame-retardant component that not only does not burden the environment but also prevents harmful chemicals such as disease-causing houses. Further, when it is an emulsion, it can be used in various fields such as a flame-retardant spray or a flame-retardant adhesive, and can be used as a product having excellent versatility and practicality to expand the market.

In addition, a reinforcing member such as a sheet using a material such as a resin mesh sheet or another resin is provided in the thermoplastic resin layer so as to prevent the thermoplastic resin when the sheet-like or mat-shaped thermoplastic resin layer is bent or pushed or pulled. In the case of breakage of a layer such as cracking or cutting, there is also an advantage that a thermoplastic resin layer can be provided, which can be improved not only in production but also in various places, particularly in terms of tensile force. The strength of the thermoplastic resin layer having insufficient strength is extremely low, and a defective product is rarely produced.

Then, the flexible planar body, the thermoplastic resin layer or the substrate material layer of the above flame-retardant planar body will be described in detail below. First, in the embodiment, the EVA emulsion is obtained by mixing a powder of sodium polyborate with an EVA emulsion having a solid content of 5 to 80%, preferably 10 to 60%. The powder of sodium polyborate can be obtained from an aqueous solution of a product name "Fairesu B liquid" (manufactured by Trust Life Co., Ltd.) by a spray drying method or a freeze drying method. "Fairesu B liquid" is an aqueous solution in which the concentration of sodium polyborate is concentrated to a solubility of boric acid or borax alone (20 ° C) or more, and the amount of the powder of sodium polyborate is preferably 60 to 150 with respect to the EVA emulsion (solid content). The range of mass %.

In addition, the EVA-based resin of the present embodiment is a material obtained by kneading a powder of sodium polyborate to an EVA resin at 150 ° C or lower and then providing the sheet. The amount of the sodium polyborate added is in the range of 5 to 120% with respect to the EVA resin, and is preferably in the range of 20 to 100%. The melting point of the EVA resin is lower as the blending ratio of vinyl acetate in the resin is higher. The blending ratio of vinyl acetate in the EVA resin was 94 ° C when the mass ratio was 10% by mass. Further, when the above ratio was 33%, the melting point was 61 °C. In view of the kneading step of the EVA resin and the sodium polyborate, the blending ratio of the vinyl acetate in the EVA resin is preferably in the range of 10 to 40% by mass.

Existing carpets and the like generally have a base fabric having a pile fabric on the surface, and a styrene butadiene polymer (SBR) is used as an adhesive layer and a substrate material is laminated. On the other hand, the EVA-based resin layer of the present invention does not generate smoke, and does not cause a load on the environment, and is excellent not only as a flame-retardant member that does not cause harmful chemicals such as a diseased house, but also as a bonding member. The resin is also excellent. Therefore, the back surface of the flame-retardant planar body which can be used as a primary base fabric can be formed on the surface, and at least one of the EVA-based emulsion coating layer or the EVA-based resin layer coated with the EVA-based emulsion and dried can be provided. The substrate material layer is laminated on either side. Thus, the portion containing the EVA resin and the sodium polyborate has a function of exhibiting a flame retarding action and a bonding action.

In the present invention, a flame-retardant planar body in which a pile fabric is formed on the surface is used as a primary base fabric, and a flame-retardant planar body having another flexible planar body on the back surface thereof is laminated as a secondary base fabric. In this case, the tensile strength and the like of the flame-retardant planar body are improved, and when it is used for a mat or the like of a carpet or the like, the stability of the cut size is excellent.

In one embodiment of the present invention, the pile fabric is made of a wool thread, but may be a nylon thread, a polyester thread, a polypropylene thread or the like. Further, the flexible planar body which is a flame-retardant planar body used for the primary base fabric is also formed of a polyester fiber-based nonwoven fabric, but may be a polyester woven base fabric, a carbon fiber woven base fabric, or a polypropylene woven base fabric. The material is of course not limited, but at least one of the one surface and the other surface of the flexible planar body is provided with a thermoplastic resin layer containing at least an inorganic substance such as sodium polyborate and having at least an ethylene group or a low temperature specificity. In either case, the flexible planar body may be formed by mixing a thermoplastic resin having at least an inorganic substance such as sodium polyborate, and having an ethylene group or a low temperature specificity. At least either party. The thermoplastic resin layer may not be provided in at least one of the one surface or the other surface of the flexible planar body, and the flexible planar body itself may be formed by mixing a thermoplastic resin having at least an inorganic substance such as sodium polyborate. And at least one of an ethylene group or a low temperature specificity. In other words, in the case where any of the above-described structures is present, an ethylene group is present in the thermoplastic resin, and the hydrogen bond is strongly applied to both the sodium polyborate and the flexible planar body to form an excellent flame retardancy. Flammable surface. In addition, when it has a low temperature specificity, it has the following effects: it can effectively knead with a thermoplastic resin without foaming sodium polyborate; wherein the low temperature specificity is that the melting point of the thermoplastic resin is lower than that which is generally not likely to generate harmful gases. A substrate material used in a mat or the like, such as vinyl chloride or the like. In addition, by using an inorganic substance such as sodium polyborate, it is possible not only to cause a load on the environment, but also to prevent the occurrence of harmful chemical substances such as a diseased house. That is, a thermoplastic resin layer is provided in at least one of the one surface or the other surface, and the flexible planar body itself is also mixed with a thermoplastic resin, wherein the thermoplastic resin layer contains at least an inorganic substance such as sodium polyborate and has an acetamino group or a low temperature. When at least one of the specificities of the thermoplastic resin contains at least one of an inorganic substance such as sodium polyborate and an ethylene group or a low temperature specificity, an extremely excellent multiplying effect can be obtained which can further enhance the above effects. When the thermoplastic resin contains at least one of an inorganic substance such as sodium polyborate and contains at least one of an ethylene group or a low temperature specificity, the thermoplastic resin has a thermoplastic resin layer and has the following products. The maximal effect: the flexible planar body having the above effects can be mass-produced extremely inexpensively and with improved productivity. In addition, when the interior material is a long mat, the jute used now can be used for the substrate material, or the blend of hemp and cotton can be used for the substrate material, the specific material of the substrate material, the manufacturing method, etc. Any restrictions.

In addition, when the interior material is a tile-shaped mat, a glass fiber non-woven fabric or a mesh-like glass fiber mesh or a polyester mesh may be used as the secondary base fabric as a specific material of the secondary base fabric. There is no limitation on the material, and the like, but it is of course also possible to use another flame-retardant planar body different from the flame-retardant planar body used in the primary base fabric in the secondary base fabric.

When the flame-retardant planar body is used for the secondary base fabric, when the EVA-based resin layer is heated and laminated, the EVA-based resin is mutually melt-penetrated, and the EVA-based resin layer is used as the reinforcing fiber. Play the function. Further, in the case of a square-shaped mat, it is of course possible to laminate the flame-retardant fiber nonwoven fabric as a substrate material layer.

Further, in the present invention, when at least an inorganic material such as sodium polyborate is mixed with a thermoplastic resin layer having at least one of an ethylene group or a low temperature specificity, 2 to 5% of starch may be mixed, and the starch has the following effects: The adhesion and the like when the sodium polyborate is adhered to the polypropylene non-woven fabric or the like is improved.

Further, in the EVA resin, in addition to sodium polyborate, 5% to 30% of aluminum hydroxide, magnesium hydroxide, or the like may be added to the flame retardant, or 1 to 50% may be mixed. Calcium carbonate, which is a modifier of EVA resin, has an effect of improving flame retardancy in any case.

The EVA resin is excellent in the miscibility of the radiation shielding material such as tungsten or lead. Therefore, when the radiation shielding material is contained in the EVA-based resin layer, the radiation-shielding interior is provided in addition to the flame retardancy. material. Therefore, for example, when a contaminated soil is measured using a 1 mm-thick sheet of tungsten powder mixed with the same mass as the EVA resin in the EVA-based resin, it has been confirmed that the amount of radiation from the front of the cover sheet is 11.0 μSv/h to 5.0 after the cover. μSv/h is reduced by approximately 55%. The tungsten powder can be mixed in an amount of 10 to 500% with respect to the mass of the EVA resin, but it is preferably in the range of 50 to 400%. Further, if the above metal powder is mixed, it is also possible to have an effect of preventing vibration and sound absorption (anti-sound, sound insulation).

In the present invention, the long interior material may be coated with an EVA emulsion and dried on the back surface of the base fabric on which the pile fabric is formed by a tufting step, or a molten EVA may be laminated on the back surface of the base fabric. In the case of a resin sheet, the laminated substrate material layer may be heated on the back surface thereof as needed, and the square interior material is a primary base fabric which will form a pile fabric on the surface through a tufting step and superimposed on the back surface thereof. A material for heating and laminating the secondary base fabric and the EVA-based resin layer. If necessary, the substrate material layer is superimposed and laminated by heating, and cut into a square shape of a predetermined size, but at this time, a material which coats and dries the EVA-based emulsion in a primary base fabric can also be used.

The test results of the above flame-retardant planar body are as follows. First, a test piece A (not shown) in which an EVA-based emulsion is applied to the back surface of a base fabric (flexible planar body) and then dried is prepared. The base fabric is composed of a polyester nonwoven fabric using a wool thread as a material for the pile fabric. This EVA emulsion is a powder of sodium polyborate having almost the same mass as the solid component, for an EVA emulsion having a solid content of 50%. The test piece A was suspended in a state in which the cross section was vertical, and the flame of the furnace at 1300 ° C was directly contacted, although it was confirmed that sodium polyborate foamed and carbonized, but it did not catch fire.

In addition, a test piece B (not shown) which is the same as the above-mentioned test piece A except for a nylon pile fabric having a nylon thread on the surface thereof is used, and similarly to the test piece A, the flame of the fire of 1300 ° C is directly contacted, although It can be confirmed that sodium polyborate foams and carbonizes, but does not catch fire.

Therefore, by adding kneaded sodium polyborate to the EVA resin to form a non-combustible resin, the EVA resin can also adjust the physical properties by blending the ratio of ethylene and vinyl acetate, so that it can be used as a base fabric with a mat or the like. The (flexible planar body) is combined for use in a mat that does not easily generate harmful gases. Such an EVA resin having a non-combustible function added with sodium polyborate can be used as a non-combustible resin molded product of a non-combustible resin material, a high-pressure wire non-combustible covering material, a non-combustible equipment material, a non-combustible material such as a window frame of a building material, or a non-combustible bonding material. Use of the agent.

In addition, since the flame-retardant planar body can be easily formed into a film or a sheet, it has the following large effects: it can be used as a non-combustible material for a surface coating, a non-combustible film material, and can be enhanced by reinforcing incombustible fibers. It is used as a non-combustible sheet, a non-combustible ceiling film material, a non-combustible tent fabric, a non-combustible hood fabric, a protective sheet for welding and cutting, and a non-combustible cloth.

Further, since sodium polyborate has a shielding effect of neutron rays, it also has an effect of shielding gamma rays such as tungsten. Therefore, the sheet having flexibility can be applied to, for example, a radiation shielding material such as a pipe of various factories such as contaminated soil, and a radiation shielding room such as a radiation management room. Materials, internal use of non-combustible fibers to improve tensile strength, radiation shielding of incombustible sheet materials, radiation shielding of incombustible materials, radiation shielding of non-combustible cloth, radiation shielding of non-combustible materials from resin molding, etc.

Further, by adding sodium polyborate to an EVA emulsion, it can be used as a flame-retardant emulsion. Therefore, it can be applied not only to interior materials but also to various fields such as flame-retardant sprays and adhesives.

Hereinafter, a method of manufacturing a mat that does not easily generate a harmful gas will be described. In the method for producing a mat which is less likely to generate a harmful gas, a substrate material, a skin material layer using a flame-retardant planar body, and the like are gradually formed from the following steps, and a mat which is less likely to generate harmful gas is produced.

First, it can be cut into a predetermined size by any of the following steps to produce a mat that is less likely to generate harmful gases: a step of forming a substrate material layer (10) which is to be in the fiber The pitch-based carbon fiber formed in the range of 2.0 to 16.0 dtex and the cutting length of 20 to 160 mm or at least the PAN-based carbon fiber formed in the range of the fiber thickness of 2.0 to 16.0 dtex and the cutting length of 20 to 160 mm Any one of the polyester-based fibers formed in the range of the fiber thickness of 2.0 to 16.0 dtex and the cut length of 20 to 160 mm is 30 to 80 by weight of at least one of the pitch-based carbon fiber or the PAN-based carbon fiber. %, polyester fiber is blended at a blending ratio of 20 to 70% by weight, and is composed of a nonwoven fabric aggregate; a step of forming a flame-retardant planar body (primary base fabric 21), the flame-retardant surface At least one of one surface or the other surface of the flexible planar body main body formed of a polyester fiber (polyester-based fiber nonwoven fabric) or the like, and at least one of an EVA-based emulsion coating layer or an EVA-based resin layer Either side, as a The base fabric 21 is used, wherein the EVA emulsion coating layer is coated with an EVA emulsion containing at least sodium polyborate in an ethylene-vinyl acetate copolymer, and the EVA resin layer is an ethylene-vinyl acetate copolymer. At least a sodium polyborate; a step of forming a skin material layer (20), the skin material layer forming a pile fabric by a pile yarn (100% wool) on the surface of one side of the flame-retardant surface (22 ), in order to use the flame-retardant planar body as a primary base fabric (21); and a step of laminating and pressure-heating for lamination bonding, a flame-retardant planar body formed as a skin material layer (20) a flat-woven mesh bottom (for example, a multifilament yarn made of polyester fiber) is interposed or not interposed between the EVA-based resin layer of the flame-retardant planar body and the substrate material layer (10) on the back surface. Forming), in order to use the EVA-based resin layer as a bonding material layer, and laminating the substrate material layer (10) and the flame-retardant planar body forming the skin material layer (20) under pressure heating Bonding, or coating on the back side of the flame-retardant face forming the pile fabric (22) After the release layer of the styrene-butadiene-styrene block copolymer composition or the amorphous olefin polymer composition, at least one of the binders is formed to form the skin material layer (20), The substrate material layer (10) is coated with a paste using either a styrene-butadiene-styrene block copolymer composition or an amorphous olefin polymer composition (adhesive material layer 30) After that, the flat bottom of the mesh is formed (formed from a multifilament yarn of polyester fiber), which is then heated, and then the flame-retardant planar stack of the skin material layer (20) is formed thereon. Combined with pressurized heating for superposition bonding.

Therefore, the entire material is a material that is less likely to generate harmful gases, and is not only flame-retardant but also flame-resistant and flame-resistant, and at the same time, at least one of carbon fiber or oxidized acrylic fiber is used as the substrate material layer (10). Since the polyester fiber is blended with the polyester fiber and formed of a nonwoven fabric aggregate, the heat setting property is improved and the density is increased, so that the strength as a substrate material is also improved.

Further, the adhesive material layer 30 is a styrene-butadiene-styrene block copolymer composition 32 or an amorphous olefin which is composed of a plain woven mesh bottom composed of a multifilament yarn of polyester fibers. When either one of the polymer compositions is provided, it is possible to provide not only good water-resistant adhesion but also long-lasting properties such as tensile strength and cutting dimensional stability.

Further, the skin material layer 20 is formed of a pile fabric of 100% wool pile yarn on the surface of the primary base fabric formed of a polyester fiber nonwoven fabric, and a backing-proof adhesive is applied to the back surface thereof. In addition, a layer of a skin material rich in cushioning property can be obtained, and the entire skin material layer 20 is integrally integrated, so that it is less likely to cause off-line or breakage.

Further, the substrate material layer 10 is composed of a nonwoven fabric assembly in which at least one of carbon fibers or oxidized acrylic fibers obtained by heat-carbonization treatment and polyester fibers are mixed, and the blending ratio is as follows. At least one of the carbon fiber or the oxidized acryl fiber is 30 to 80% by weight, and the polyester fiber is 20 to 70% by weight. Further, since the width of each fiber is 2.0 to 16.0 dtex and the cutting length is in the range of 20 to 160 mm, the following effects are exerted: not only flame retardancy but also fire resistance and flame resistance, so that harmful gases are less likely to be generated. Features and the best cushioning.

Further, when the weight of the substrate material layer 10 is 0.01 to 1.5 kg/m ² , the effect of the substrate material layer 10 itself can be made flexible.

Further, the substrate material layer 10 is suppressed to a thickness of 3.0 to 15.0 mm by a needle rolling method or the like, whereby the substrate material layer 10 itself can be provided with both flexibility and stretchability.

Further, the substrate material layer 10 is a nonwoven fabric assembly in which at least one of pitch-based carbon fibers or PAN-based carbon fibers and polyester fibers (including heat-bonding fibers) are blended, and is used for For example, PAN-based carbon fibers are used for the carbon fibers of the substrate material layer 10 (oxidized acrylic fibers are obtained by heat-treating a polypropylene precursor precursor fiber in an oxidizing atmosphere), for example, Even if the substrate material is ignited, the damage caused by the burning and melting of the substrate material itself is slight, and since the oxidized acrylic fiber has appropriate strength and elongation, it can be formed in the manufacturing step with strength, Flexible and stretchable nonwoven fabric aggregates.

Further, when pitch-based carbon fibers (such as by-products such as petroleum, charcoal, and tar) are used instead of the PAN-based carbon fibers, the damage caused by burning and melting of the substrate material itself may be slight. In any case, the base material layer 10 may be a nonwoven fabric aggregate in which at least one of pitch-based carbon fibers or PAN-based carbon fibers and polyester fibers are blended.

In order to improve the heat setting property, the nonwoven fabric assembly is a material obtained by mixing the above-mentioned oxidized acrylic fibers with polyester fibers. However, in this case, in the manufacturing step, the step after the needle rolling (processing such as the needle rolling method) is heated and then pressurized and cooled, whereby the heat setting property is improved by the shrinkage of the polyester fiber, so that it is maintained. Higher post-punching density improves dimensional stability and flame retardancy.

In addition, since only the oxidized acrylic fiber is not sufficiently rigid, it is difficult to maintain a high-density state alone. Therefore, by mixing the highly rigid polyester-based fibers to maintain the density required for the nonwoven fabric assembly, the achievement is achieved. Excellent properties of the substrate material.

Therefore, since polyester fiber (including heat-bonding fiber) can be used, sufficient heat setting property can be obtained, and relatively high heat resistance is obtained, it is possible to avoid the disadvantage of impairing the heat resistance of the substrate material, and it is possible to obtain A substrate material having a relatively high heat resistance such as a heat resistance temperature of 150 ° C to 200 ° C. Further, in one embodiment of the present invention, a polyester fiber is used as the fiber in the oxidized acrylic fiber, and an aramid fiber may be used instead.

The blending ratio of the oxidized acrylic fiber and the polyester fiber is preferably such that the weight ratio is 30 to 80% of oxidized acrylic fiber and 20 to 70% of polyester fiber. When the blending ratio of the polyester fibers is suppressed to such an extent, a substrate material which can significantly improve heat setting properties without lowering the flame resistance is obtained.

If the substrate material layer 10 of the mat A is formed by using such a substrate material as described above, since it has high flame retardancy and flame resistance, no harmful gas is generated even if it is directly exposed to the flame, and it can be extinguished instantaneously without It will burn and not burn, so even if it catches fire, the damage caused by the burning and melting of the substrate material itself is very slight.

Further, in order to use the flame-retardant planar body as the primary base fabric 21, the surface of the one side of the flame-retardant planar body is formed of a pile fabric 22 by a pile yarn (100% wool) to form a skin material. The layer 20 is then inserted or not interposed between the EVA-based resin layer of the flame-retardant planar body and the substrate material layer 10 on the back surface of the flame-retardant planar body formed as the skin material layer 20. a flat woven mesh bottom (for example, formed of a multifilament yarn of polyester fiber or the like) to use the EVA-based resin layer as a bonding material layer, and the substrate material layer 10 and the resistance forming the skin material layer 20 The flammable surface-like stack is combined with pressurized heating to be cut and fixed in a predetermined size after lamination and bonding, and has the following advantages: not only can the material cost be reduced, but also a mat which is easy to produce harmful gas with a simple manufacturing step can be manufactured. .

Further, the styrene-butadiene-styrene block copolymer composition or the non-coating may be applied to the back surface of the flame-retardant planar body forming the pile fabric 22 without being subjected to the above steps. After the skin material layer 20 is formed by bonding at least one of the crystalline olefin polymer composition, the styrene-butadiene-styrene block copolymer composition is used for the substrate material layer 10 or After the paste of at least one of the amorphous olefin polymer composition is coated (adhesive material layer 30), the flat mesh bottom (formed by the multifilament yarn of polyester fiber) is laminated, and then It is heated, and then the flame-retardant planar body forming the skin material layer (20) is laminated thereon by pressure heating to be laminated and bonded, and cut into a predetermined size, thereby making it difficult to generate harmful gases. mat.

In the manufacturing method in this case, the adhesive material layer 30 is a styrene-butadiene-styrene block copolymer composition 32 containing a mesh bottom 31 formed of a multifilament yarn of a polyester fiber. Or at least one of the amorphous olefin polymer compositions, but is preferably a bonding material which rarely generates a toxic gas during combustion, for example, an amorphous olefin polymer and a crystalline polypropylene as a secondary polymer or A composition of a tackifier, a melt viscosity reducing agent, and a filler. Further, various additives such as a flame retardant or a colorant may be blended as needed. As the amorphous olefin polymer, APAO (amorphous polyolefin), APP (amorphous polypropylene), amorphous butylene polymer, and the like are exemplified. Further, the polymer composition may contain, together with the amorphous olefin polymer of the main polymer, another resin component containing no halogen element such as crystalline polypropylene as a secondary polymer. In addition, various additives such as a tackifier such as an aliphatic petroleum resin, a melt viscosity reducing agent such as paraffin, various fillers, and various flame retardants may be mixed as needed.

The polyester fiber contained in the adhesive layer 30 has a high tensile strength and is not easily stretched, and although a mat A having high strength and excellent dimensional stability can be obtained, benzene is used in the adhesive material layer 30. When the ethylene-butadiene-styrene block copolymer composition 32 is formed, the water-resistant adhesive layer 30 can be formed.

Further, in the above-described mesh bottom 31, plain weave composed of multifilament yarns of polyester fibers in the adhesive layer 30 is used, whereby high strength and dimensional stability can be obtained for both the longitudinal and the transverse directions.

Further, in an embodiment of the present invention, the adhesive layer 30 contains a mesh bottom 31 composed of a multifilament yarn of polyester fibers, but is not limited thereto, and may of course have a multi-layer mesh bottom. To form the adhesive layer.

If the adhesive material layer of the mat A is constructed as described above, the following mat A is obtained: because the styrene-butadiene-styrene block copolymer composition 32 or the amorphous olefin polymer composition At least one of them has good adhesion, and the mesh bottom 31 composed of the multifilament yarn of the polyester fiber is water-resistant, has high tensile strength, good dimensional stability, and has high durability.

The skin material layer 20 is formed by using a flame-retardant planar body having a flexible planar body composed of a nonwoven fabric made of polyester fiber as the primary base fabric 21, and is formed of a pile yarn of 100% wool on the surface. The pile fabric 22 is coated on the back surface thereof with an adhesive composed of at least one of the styrene-butadiene-styrene block copolymer composition 32 or the amorphous olefin polymer composition for preventing the off-line. In the case of the raw material which inhibits the generation of a harmful gas, for example, a non-combustible agent containing a sodium salt of a boric acid ion polymer or the like as a composition may be adhered to the surface of the skin material layer 20 by spraying or the like.

As described above, the skin material layer 20 constituting the mat A can provide a cushion material layer having a rich cushioning property, and the entire skin material layer can be integrally integrated, so that no off-line or breakage occurs, and further, it can be further improved. A layer of non-combustibility, flame retardancy, fire resistance and flame resistance.

As described above, according to the mat A which is less likely to generate a harmful gas in the present invention, the heat setting property can be remarkably improved without lowering the flame resistance, and at the same time, by having a heat resistance temperature of 150 to 200 ° C, the heat resistance can be made. High flame retardancy and flame resistance. Therefore, even if it is directly exposed to the flame, no harmful gas is generated, and it can be extinguished in an instant without burning. In addition, since the mat A which does not easily generate harmful gas does not burn by itself, even when it is caused by fire, The damage caused by the burning and melting of the substrate material itself is also slight. In addition, it has the best cushioning properties, flexibility or stretchability. The optimum cushioning property is a mat A which is resistant to water and has good adhesion and has excellent durability in tensile strength and cutting dimensional stability. The flexibility or stretchability is, for example, when it is used as a carpet tile by performing a cutting process, or when it is used as a long carpet having a predetermined width and a predetermined length, not only from a manufacturing plant or the like. When transporting at the construction site, etc., when moving to the actual construction site at the construction site, it can be bent or softened. Not only that, but also softness or flexibility for making it difficult to peel off during construction. . The mat A which is less likely to generate a harmful gas has excellent adhesion to water and has excellent durability in tensile strength and cutting dimensional stability.

The test results of the smoky property and the combustion toxicity of the mat which is less likely to generate harmful gas in the present invention and the experimental results of the measured toxic gas are shown in Table 1.

(Test method) The test is carried out in accordance with the International Maritime Organization (IMO) "International Regulations on Fire Test Methods (Marine Safety Committee Resolution MSC61 (67)", Part 2, "Smoke and Toxicity Test". It is implemented according to the second part of ISO 5659:1994. The analysis of toxic gas uses FTIR (Fourier Transform Infrared Spectroscopy). The test body uses a mat which is not easy to generate harmful gas as described in one embodiment of the present invention (Yoshida fabric) Made by the company, product name: surface floor material, model: YF square W, size: length and width 75mm).

(Test Results) Table 1 shows a summary of the test results and the reference values specified in the above test methods. The test body is a determination result of a standard which satisfies the smoky properties and toxicity of various materials which are predetermined according to the criteria of the second part of the fire test method regulations. 【Table 1】 Note 1. The ND Not Detected in Table 1 is not detected. [Industry Utilization]

The flame-retardant planar body of the present invention and the mat which is less likely to generate harmful gas using the flame-retardant planar body have excellent flame retardancy, fire resistance and flame resistance, and therefore are of course suitable for general household fire. It is especially suitable for use in factories where ignition and ignition are used, and it is particularly suitable for use in places where fire protection is strict in ships, high-rise buildings, airplanes, and automobiles.

A‧‧‧mat
10‧‧‧Background material layer
20‧‧‧ skin material layer
21‧‧‧A base fabric
22‧‧‧Fleece fabric
23‧‧‧Adhesive
30‧‧‧ Bonding material layer
31‧‧‧ grid bottom
32‧‧‧styrene-butadiene-styrene block copolymer composition

Fig. 1 is a partially cutaway perspective view showing a mat which is less likely to generate a harmful gas according to an embodiment of the present invention. Fig. 2 is a schematic cross-sectional view showing a portion of a mat which is less likely to generate a harmful gas according to an embodiment of the present invention.

A‧‧‧mat

10‧‧‧Background material layer

20‧‧‧ skin material layer

21‧‧‧A base fabric

22‧‧‧Fleece fabric

30‧‧‧ Bonding material layer

31‧‧‧ grid bottom

32‧‧‧styrene-butadiene-styrene block copolymer composition

Claims (16)

A flame-retardant planar body having a flexible planar body which can be used for a mat (A) or the like which is less likely to generate a harmful gas, and which is in at least one of one side or the other side of the flexible planar body The thermoplastic resin layer is provided with at least one of an inorganic substance such as sodium polyborate and having an ethylene group or a low temperature specificity; and/or formed by mixing a thermoplastic resin into the flexible planar body itself, wherein The thermoplastic resin has at least one of an ethylene group and an inorganic substance such as sodium polyborate, and has at least one of an ethylene group and a low temperature specificity. The flame-retardant surface of the first aspect of the invention, wherein the thermoplastic resin layer is formed of an EVA-based emulsion coating layer or an EVA-based resin layer coated with an ethylene-vinyl acetate copolymer The EVA-based emulsion containing at least sodium polyborate containing at least sodium polyborate in the ethylene-vinyl acetate copolymer is dried. The flame-retardant planar body of the second aspect of the invention is characterized in that the EVA-based emulsion coating layer is provided on at least one of one surface and the other surface of the flexible planar body, and the EVA system is used. The resin laminate layer is on the EVA emulsion coating layer. The flame-retardant planar body according to any one of claims 1 to 3, which is characterized in that, when a thermoplastic resin layer is provided on one surface or the other surface of the flexible planar body, One side or the other side of the flexible planar body opposite the resin layer forms a pile fabric. The flame-retardant planar body of claim 4, wherein another flexible planar body is laminated on one side or the other side of the flexible planar body opposite to the surface on which the pile fabric is formed, and At least one of one surface or the other surface of the other flexible planar body is provided with at least one of an EVA emulsion coating layer or an EVA resin layer. The flame-retardant planar body according to any one of claims 1 to 3, wherein the substrate material is laminated on the thermoplastic resin layer. The flame-retardant planar body of the sixth aspect of the invention, wherein the flexible planar body, the thermoplastic resin layer or the substrate material layer has a suppressing mechanism and suppresses the flame-retardant planar body. At least one of shrinkage or bending. The flame-retardant planar body of the sixth aspect of the invention, wherein at least one of the vibration-proof device or the sound absorbing device is provided in any one of the flexible planar body, the thermoplastic resin layer or the substrate material layer . The flame-retardant planar body according to any one of claims 1 to 3, wherein the flame-retardant planar body contains a radiation shielding substance. The flame-retardant planar body according to the sixth aspect of the invention, wherein the substrate material layer is composed of at least one of pitch-based carbon fibers or PAN-based carbon fibers and a nonwoven fabric aggregate of polyester-based fibers, and is blended. The ratio is as follows: at least one of the pitch-based carbon fibers or the PAN-based carbon fibers is 30 to 80% by weight, and the polyester fibers are 20 to 70% by weight; and the width of each fiber is 2.0 to 16.0 dtex, and the cutting length is It is formed in the range of 20 to 160 mm. The scope of the patent retardant planar body, Paragraph 6, wherein the weight of the substrate material layer (10) is 0.01 ~ 1.5kg / m ^2. The flame-retardant planar body of claim 6 is a structure in which the thickness of the substrate material layer (10) is suppressed by a needle rolling method to a range of 3.0 to 15.0 mm. A mat (A) which is less likely to generate a harmful gas, and which is a flame-retardant planar body according to any one of claims 4 to 12, characterized in that the skin material layer (20) is formed to be formed The flame-retardant surface of the pile fabric (22) is used as a primary fabric (21), and the skin material layer (20) and the substrate material layer (10) are interposed between the thermoplastic resin layers. And/or other layers of adhesive material (30) are laminated and formed into a structure in which the thermoplastic resin layer and/or other layers of bonding material (30) contain or do not contain a plain weave mesh. In a bottom manner, the flame-retardant planar body forming the skin material layer (20) and the substrate material layer (10) are integrated. A method for manufacturing a mat which is less likely to generate a harmful gas, which is cut into a predetermined size by any of the following steps to produce a mat which is less likely to generate a harmful gas: a step of forming a substrate material layer (10), the substrate The material layer (10) is a pitch-based carbon fiber formed by a fiber having a thickness of 2.0 to 16.0 dtex and a cutting length of 20 to 160 mm or a fiber having a thickness of 2.0 to 16.0 dtex and a cutting length of 20 to 160 mm. At least one of the PAN-based carbon fibers formed in the range, and a polyester-based fiber formed in a fiber thickness of 2.0 to 16.0 dtex and a cut length of 20 to 160 mm, in the pitch-based carbon fiber or the PAN-based carbon fiber a blending ratio of at least one of 30 to 80% by weight and a polyester fiber of 20 to 70% by weight, and a mixture of non-woven fabrics; a step of forming a flame-retardant planar body, the resistance At least one of the EVA-based emulsion coating layer or the EVA-based resin layer is provided in at least one of one surface and the other surface of the flexible planar body body formed of a polyester fiber or the like. The EVA-based emulsion coating layer is obtained by coating and drying an EVA-based emulsion containing at least sodium polyborate in an ethylene-vinyl acetate copolymer containing at least sodium polyborate in an ethylene-vinyl acetate copolymer. Forming a skin material layer (20), forming a pile fabric (22) on the surface of one side of the flame-retardant surface by a pile yarn, so that the flame-retardant surface is regarded as a primary base The cloth (21) is used to form the skin material layer (20); and the step of laminating and pressurizing heating to perform the lamination bonding on the back surface of the flame-retardant surface formed as the skin material layer (20) a flat meshed bottom is interposed between the EVA-based resin layer of the flame-retardant planar body and the substrate material layer (10), so that the EVA-based resin layer is used as a bonding material layer. And the substrate material layer (10) and the flame-retardant planar body forming the skin material layer (20) are laminated and pressurized to perform superposition bonding, or flame retardant in forming the pile fabric (22). The back side of the facet is coated with a styrene-butadiene-styrene block copolymer for preventing off-line After forming the skin material layer (20) with at least one of the binder or the amorphous olefin polymer composition, styrene-butadiene is used for the substrate material layer (10). After the paste of any one of the styrene block copolymer composition or the amorphous olefin polymer composition is coated (adhesive material layer 30), the flat bottom of the mesh is laminated, and then heated. And then the flame-retardant planar body on which the skin material layer (20) is formed is laminated and pressurized to perform superposition bonding. A thermoplastic resin layer, which is an ethylene-vinyl acetate copolymer, which is used in a flame-retardant planar body according to any one of claims 1 to 14 The material or the like has at least one of an ethylene group and a low temperature specificity, and at least contains an inorganic substance such as sodium polyborate and a sheet or liquid having a predetermined thickness. The thermoplastic resin layer of claim 15 which is provided with a reinforcing means for preventing breakage of cracks or breakage of the thermoplastic resin layer during bending or pushing and pulling of the sheet-shaped thermoplastic resin layer.